Well, it appears that my air leak is at the intake manifold. I got nothing on the boots or the intercooler. I just removed it because the donut o-ring was leaking coolant, not looking forward to trying it again.

 

Oops, My Bad --

I forgot to ask you the First Question:

What did you work on just prior to malfunction appearance ?
(as in, "Boost was OK until I did This ........, now I have a new problem with it")

 

That question is harder than it appears. After doing the intake I noticed that the hot side CAC boot from the turbo to the pipe was torn. It didn't feel alot different before than after because of that. I also didn't have the SCII before so I don't know normal yet. Working on it though.

 

Please let me know the solution, so I might put this in my "memory bank".

fyi - my Boost (according to SG2 and Glowshift gauge) maxes at 22, unloaded

 

It will be a while before I can attempt to tighten the intake manifold. Getting chilly down here.

 

I finally got a chance to check out the intake gasket and other possible issues. I found that I had an exhaust leak at the turbo inlet and at the EGR cooler. I also replaced the intake gaskets from Fel Pro to Motorcraft and followed the Ford torque sequence and spec. I now have power from 1/4 throttle to full throttle and she builds boost quick. Max boost I saw on the test drive was 18.5 PSI as opposed to 13 PSI if I was lucky. It also gets to the higher boost almost instantly vice only in 4th gear like before. I did the turbo relearn and got up to 21.5 PSI. She is way more fun to drive and I foresee a stupid speeding ticket in my future.
Thank You for all your assistance, it is much appreciated.

 

Looking good -- Glad I was able to be a help to you, that's why we're here on this forum.

 

Visually check the harness. Mine was obvious once I figured out while cranking had low rpm reported. The pigtail just as it goes into the sensor the wire was bare. Mine never threw a code or anything just occasionally wouldn't start. I was going crazy trying to figure it out!

I think it says 1 once they sync.

 

You're getting up there but you're still missing out on about 6 fun points. (6 lbs of boost) properly sealed system can see 28 psi, and although the turbo can make alot more, the computer keeps it there. Keep chasing leaks. But atleast now it's driveable

 

Does it get to 28 PSI unloaded? I was planning to tow my trailer with it soon and see if it made that pressure with more load.

 

I did a quick WOT run yesterday (to dry off after a hand wash) - unloaded, managed to hit 23 psi (then ran out of road in 45mph speed zone !!)

 

I checked codes and I have a P132B. Looks like I do still have an air leak somewhere. I removed the EGR valve and cleaned it up, didn't have the gasket or o-rings to replace. That will be the next thing to try and seal.